FADO - Fatigue Aware Design Optimization

Purpose and goal

The project´s aim is to develop new methods related to fatigue, structural optimization, and their AM-applications. Its objectives can be summarized as follows: - Implementation and extension of the Ottosen-Stenström-Ristinmaas (OSR) continuum-based fatigue model to also consider thermal and anisotropic effects in, among other things, additively manufactured materials. - Using the above-mentioned model in combination with topology and shape optimization to develop new fatigue-based optimized designs.

Expected effects and result

The project is expected to have the following effects and results: - Development of new methods and algorithms linked to fatigue phenomena and structural optimization More specifically, the following will be obtained: - A new fatigue model that takes into account multiaxial fatigue phenomena and other aspects linked to the design of AM-material. - An optimization tool that can both reduce the lead time for product design and potentially decrease material usage. - A doctoral researcher and several master´s students with cutting-edge expertise in the field.

Planned approach and implementation

The project is divided into the following sub-tasks: 1. Method development and calibration of the OSR model. Model calibration occurs in collaboration with GKN to match results with internal GKN data and other potential comparisons. 2. Combination of the OSR model with different types of structural optimization, specifically linked to topology and shape optimization, to achieve a fatigue optimized design. 3. A simplified demonstrator for testing and verifying the method. 4. Spreading knowledge to other projects within NFFP and other platforms such UTMIS and LIGHTer.